My next door neighbors, Alan and Roger, started up a router company not long ago. Their idea was to carve full size, and larger, images from artists small little models. They'd use light weight foam.
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Most of their models end up beign cast from bronze. We have a great local foundry, which opened up a few years ago.
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It's a real pleasure to visit and meet artists who come to finish up on their models.
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Each of their models are done in slices, then put together. Then surfaced, ready for casting.
Artsits and work pass through their shop daily. It's always fun to visit.
Great guys too!